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"Ok, I cracked the Haynes open again. I just set the pedel play to 4mm (3mm-6mm is what the book says). This is the clearance between the pushrod and master plunger that gives this pedal play."
Either I'm misreading this or you're descibing two separate adjustments and calling them the same thing.
There's pedal play, and there's push rod adjustment. If your push rod between the master and booster is 4mm your pedal should go to the floor or very close to it. That adjustment is 0.10 mm per the Toyota service manual. What is the 'master plunger' you refer to? Got pictures of what you're doing? I had similar issues a while back. I made an adjustment tool for the push rod that worked great. I can share it with you if you need me to.
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